Apparatus and process for making composition shingles



June 13, 1933. R. w. comm 1,913,475

APPARATUS AND PROCESS FOR MAKING COMPOSITION SHING-LES Filed Aug. 26,1929 2 Sheets-Sheet l ATTOENEY Pay 4/. Co/vn/vv;

June 13, 1933. R w CQNANT 1,913,475

APPARATUS AND PROCESS FOR MAKING COMPOSITION SHINGLES Filed Aug. 26,1929 2 Sheets-Sheet 2 i I l [N l/EN T012: 1693 M Carve/v7;

Patented. June 13, 1933 UNITED STATES PATENT OFFICE RAY W. CONAN'I, 01LOS ANGELES, ASBIGNOB, TO HAROLD D. BROWN, 01'

' LOS ANGELES, CALIFORNIA APPARATUS AN D PROCESS FOR MAKING COMPOSITIONSHINGLES Application am August 26,1949. lerlal was.

My invention relates to roof shingles and more particularly to acomposition shingle. It is an object of my invention to produce ashingle of the character mentioned which is composed of a suitable baseon which is built up alternated layers of a bindin material and a fillerwas to produce a s ingle having parts of different thickness.

It is another object of my invention to provide a. composition shinglewhich is thinner at the butt than at the exposed portion, the thickeningof the exposed portion being accomplished by adding a binding materialand a filler or other surfacing element to a suitable base.

It is a still further object of my invention to produce shingles from astrip of material which has been built up in the abovedescribed mannerso that it has a crosssectional contour adapting the strip to be cutlongitudinally thereof'into two or more shingles, each shingle beingthinner at its butt than at its exposed end.

A further object of my invention is to provide a method of producing theshingle of my invention.

It is also an object. of my invention to provide an apparatus by which astrip of sheet material, sufficiently wide to form one '80 or moreshingles, is first submerged in a bath of a bindm material such as hotliquid asphalt, then subjected to a scraping action to form the surfaceof the sheet material to a desired cross-sectional contour, and then :6given a surface coating composed of a layer of a filler such as sand,and wherein the stri is again submerged in hot li uid asp alt, given afinishin coating of s ate or other finishing materia and then cut intoshingles ofa desired configuration by suitable cutting means. a

It is another object of my invention to provide a process of making acomposite shingle inwhich the adherence of a granular material, such assand or slate, to the shingle member is controlled by the position andamount of adhesive applied to the shingle member.

It is a further object of my invention to provide a process of making acomposite shingle in which an adhesive coating is aporder that theposition and amount of granular material which is adhered thereto may becontrolled.

Further objects of my invention will be apparent inthe followingdescription and specification.

Referring to the drawings:

Fig. 1 is a diagram of an apparatus suitable for use in the practice ofmy invention. Fig. 2 is an elevational view showin the configuration ofthe scraping edge of a ownin element included. in my invention.

. ig. 3 is a sectional view taken on the line 3-3 of Fig. 1.

Fig. 4 is an elevational view taken on the line 4-4 of Fig. 1 showing asurfacing means of my invention.

Fig. 5 is an elevational view taken on the line 55 of Fig. 1 showinganother surfacin means.

ig. 6 is a diagram showing the manner in which astrip of shinglematerial is cut longitudinall to form four shingles across the width tereof.

Fig. 7 is a sectional view taken on the line 7-7 of Fig. 6.

Fig. 8 is an enlarged sectional view similar to a portion of Fig. 7showing the alternate layers of a binding material and a filler as usedin producing my invention.

Referring to Fig. 1 of the drawings, I show an apparatus generallydesignated by the numeral 11 in which a suitable base such as acontinuous strip of felt 12, which has first been impregnated with abinding material such as asphalt, is guided by rollers 13, 14, 15, and16 into and out of a tank 18 so that the strip 12 is completelysubmerged in a body of 100 hot liquid asphalt 19 or other bindingmaterial contained in the tank 18.

Upon emerging from the tank 18 the strip 12 passes between the roller 16and a gau ing roller 20 positioned at a slight distance a ove the roller16, which rollers 16 and 20 roll the asphalt on the felt strip 12 to auniform thickness. The strip 12 is then subjected to a scraping actionby a scraper 22 formed as shown in Fig. 2. The scraper 22 has horizontalend blades 23 adapted to scrape away the asphalt along edge portions 24of the strip 12, Fig. 3, and a horizontally aligned central blade 25which is adapted to scrape away the asphalt along a center portion 26 ofthe strip. 12. The scraper 22 presses with sufficient force against thestrip 12 so that practically all of the asphalt on the edge portions 24andthe center portion 26 is scraped away. The felt strip 12 then has across-section as shown in Fig. 3.

After passing under the scraper 22 the strip 12 has a coating of fillermaterial applied to the upper surface thereof by a suitable surfacingarrangement or hopper 28, as shown in Fig. 4. The hopper 28 applies auniform coating of sand to the hot asphalt on the surface of the feltstrip 12. The sand adheres to the asphalt on portions 30 intermediatebetween the edge and center portions 24 and 26, respectively, but doesnot adhere to the edge and center portions 24 and 26 due to the asphaltbeing scraped therefrom. The felt strip 12 then passes over awater-cooled roller 31 which cools the asphalt on the strip 12 so as tobind the sand in place thereon, and then passes over a roller 32positioned above the hopper 28 where the surplus sand on the strip 12drops back into the hopper 28 so as to be used again and not wasted.

The strip 12 is then carried by a series of rollers 34, 35, 36', and 37into and out of a tank 40 so that the strip 12 is entirely submerged ina bath of hot liquid asphalt 41 contained in the tank 40. After emergingfrom the tank 40 the strip 12 passes between the roller 37 and a gaugingroller 42, similar in construction to the gauging roller 20, whichrollers 37 and 42 roll the asphalt on the strip 12 to a uniformthickness. The strip 12 is again subjected to a scraping action by ascraper 44 adj acent the tank 40, which scraper 44 is similar inconstruction to the scraper 22 shown in Fig. 2. The scraper 44 scrapesthe edge portions 24 and the center portion 26 of the strip 12 in amanner similar to the action of the scraper 22 except that all of theasphalt is not scraped off of the felt on these portions, and a thinlayer of asphalt is left thereon.

After passing under the scraper 44 the strip 12 is treated by asurfacing means or' hopper 45 which is constructed as shown in Fig. 5.The hopper 45 has spouts 46 positioned above the edge and centerportions 24 and 26 of the strip 12 and applies a surface coating of sandto the thin layer of asphalt on these portions. From the hopper 45 thestrip 12 passes to another surfacing means or hopper 47, which isidentical to the hopper 28, and is positioned above the strip 12 for thepurpose of applying a coat of finishing filler, such as slate, to theentire surface thereof. This finishing filler will adhere only to theportions 30 of the strip 12 due to the previously applied coating ofsand to the portions 24 and 26.

The strip 12 is then conducted around a cooling roller 50, similar tothe cooling roller 31, which cools the asphalt on the strip 12sufliciently to hold the surfacing material in position. From thecooling roller 50 the strip 12 is conducted around a roller 51positioned above the hopper 47, which allows the surplus slate and .sandon the strip 12 to fall into the hopper, a cutting mechanism (not shown)which may be any suitable mechanism to cut the strip 12 longitudinallyso as to form shingles.

The strip 12 after having passed through the consecutive baths ofasphalt 19 and 41 in the tanks 18 and 40, under the scrapers 22 and 44,and being surfaced with sand and slate or other surfacing material,comprises a shingle material as shown in Figs. 6, 7, and 8. As shown inFigs. 7 and 8, the portions 30 of the strip 12 are thickest and arecomposed of a body of felt 54 covered by a layer of asphalt 55, then acoating of sand 56, then an additional layer of asphalt 57 and finally afinishing coating of slate 58. The edge and center portions 24 and 26are thinner than the portions 30 due to being scraped by the scrapers 22and 44 and comprise a body of felt 54, a thin layer of asphalt 60, and alayer of sand 61.

The cutting mechanism is adapted to cut the strip longitudinally intofour shingles or shingle strips across the width of the strip 12 andhaving a shape determined by outer cuts 64 and 65 and an inner cut 66shown by dotted lines in Fig. 6. It will be seen from an Inspection ofFig. 6 that the two outer cuts 64 and 65 follow an angled or staggeredpath and, being out through the thickened portions 30, form exposed ends68, 69,70, and

1 of four shlngles which have the desired design formed by thecrenulated edges along the exposed ends thereof; the central cut 66being straight and through the thin center portion 26 forms the buttends 74 and 75 of two of the shingles, which are identical with buttends 76 and 77 of the other two shingles.

In laying my shingles to form a roof covering, the 'thin butt ends ofone shingle are covered by the thicker portions of another shingle, theicker portions being exposed to the weather. The adaptability of such ashingle having a thick exposed end and a thin butt end is readilyapparent to those skilled in the art.

and the strip is then conducted to It should be understood that I do notwish to limit myself to any particular shape of the exposed end of myshingle, and the angled cuts 64' and 65 merely serve as an illustrationas to one manner of forming my shingles. Any suitable base material maybe substituted for the strip of felt 12, any suitable binding materialmay be substituted for the asphalt, and any suitable filler may besubstituted for the sand and slate and still come within the limits ofmy invention.

From the foregoing description-it will be seen that one of the im ortantfeatures of my present invention is t e manner of controlling theadherence of the ranular material to the shingle member. T e shinglemember may be a single shingle piece, so far as the broad aspect of myinvention is concerned, or it may be a strip of material which can bepassed through an apparatus such as is diagrammatically illustrated inFig. 1 of the drawings. The adherence of the granular material to theshingle member is controlled by determining the amount of adhesivecoating and the position of the adhesive coating applied to the shinglemember prior to the ap lying of the granular material.

11 the form of the invention illustrated herein, I utilize scrapingmeans for providing the coating of adhesive material with a sultablecontour. When I make reference to contour, I do not refer to thethickness of the coating of adhesive material, but I refer to theoutline of it from a plan View. When such a term is used in the claims,the meaning explained above is to be given to such a term.

In the preferred form of my invention I submerge the shingle member in abath of adhesive material, such as hot asphalt, and thereafter removecertain portions of the adhesive coating to form the desired contour.This process is more easily performed than would be a process in whichan asphalt coating means were provided which applied a coating only to acertain portion of the shingle member. It should be str ctly understood,however, that it comes withln the purview of my invention and the broadclaims appended hereto, to apply an asphalt coating to certain portionsof a shingle member by having the asphalt coating or adhesive coatinginitially applied to said portions and not to other portions of theshing e member.

It is a further important part of my invention to form the adhesivecoating of different thicknesses in order to control the amount ofgranular material which will adhere to different portions of the shinglemember. Where the adhesive coating is the thickest the granular materialwill adhere to theshingle member in greater quantities.

Although I have herein disclosed only one complete embodiment of myinvention I am aware that various features may be changed and numerousembodiments might be conceived by those skilled in the art withoutdepartin from the spirit and scope of my invention.

I claim as my invention: 1. A process of producing composition shinglescomprising: passing a strip of a base material, sufficiently wide toform one or more shingles, through a bath of a binding material to forman adhesive coating; re-

moving a portion of said coating from said strip so as to provide saidstrip with a coated and an uncoated portion; applying a filler to saidadhesive coating; passing said strip through an additional bath of saidbinding materlal to form a second adhesive coating; and applying afiller to said adhesive coating a second time.

A process of producing -a composition shingle comprising: impregnatingan absorptive material with a bituminous substance; passm saidabsorptive material through a bath 0 bituminous substance, saidsubstance being heated sufiiciently to become liquidized to form acoating of said substance on said material removing a portion of saidcoating from said strip so as to provide said strip with a coated and anuncoated portion; applying a surfacing element to said material, saidsurfacing element adhering to said sub stance on said material; passingsaid material throu h an additional bath of said substance to orm asecond coating of said substance on said material; and applying afinishing surfacing element to said material.

3. A process of producing a composition shingle comprising: passing anabsorptive material, said material having been previously impregnatedwith asphalt, through a bath of hot asphalt to form a coating of saidasphalt on sai material; removing a portion of said coating from saidstrip so as to provide said stri with a coated and an uncoated portion;app ying a granular surfacing element to said material, said elementadhering to said coating of asphalt on said material; passing saidmaterial through an additional bath of asphalt to form a second coatingof said asphalt on said material; and applying a finishing surfacingelement to said material.

4. A process of producing a composition shingle comprising: 'submerginga strip of felt, said felt having been previously impregnated withasphalt, in a bath of hot asphalt to form a coating of said asphalt onsaid felt; forming the upper surface of said felt strip by removing apart thereof to provide said strip with a coated and an uncoatedportion; applying a layer of sand to one side of said strip; submergingsaid strip in an additional bath of hot asphalt to form a second coatingof asphalt on said strip over said layer of sand; subjecting the uppersurface of said strip to additional scraping to maintain the desiredcontour; and applying a layer of anular finishing material to one sideof said strip. 4

. plying a second adhesive 5. A process of producing a compositeshingle, comprising: applying an adheslve coating to a felt plece;removrng a port1on of said coating from said felt piece in order toprovide said felt piece with a coated and an uncoated portion, applyinga surfaclng material on said area having the adhesive coating, thesurfacing material adhering thereto; applying a second adhesive coatingto the entire area of said felt piece; and applying granular material tosaid area having the'sccond adhesive coating applied thereto;

6. A process of producing a composite shingle, comprising: applying anadhesive coating to a felt piece; removing a portion of said coatingfrom said felt piece in order to provide said felt piece with a coatedand an uncoated portion applying a surfacing material on said areahaving the adhesive coating, the surfacing material adhering thereto;ap-

coating to the entire area of said felt piece; applying a surfacingmaterial'to that portion of said felt piece from which the firstadhesive coating was removed; and applying a finishing material to theremaining area of said felt piece.

7. A process of producing a composite shingle, comprising: applying anadhesive coatlng to a felt piece; removing a portion of said coatingfrom said felt piece in order to provide said felt piece with a coatedand an uncoated portion; applying a surfacing material on said areahaving the adhesive coating, the surfacing material adhering thereto;applying a second adhesive coating to the entire area of said feltpiece, the adhesive coating applied to the area of said felt piece whichwas not coated by said first adhesive coating being relatively thin; andap plying granular material to said area having the second adhesivecoating applied thereto.

8. An apparatus for forming composition shingles, having: a plurality oftanks containing a bituminous substance, said substance being heatedsufiiciently to become liquidized; a series of rollers carrying a stripof absorptive material, said rollers being adapted to submerge saidstrip in said substance within said tanks to form coatings of saidsubstance on said strip; substance removing means intermediate saidtanks adapted to remove said substance from a part of said strip ofabsorptive material, thus providing said absorptive material with acoated and an uncoated portion, surfacing means intermediate said tanksfor applying a surfacing element to said strip; and means for applying afinishing surfacing element.

9. An apparatus for forming composition shingles, having: a plurality oftanks containing hot liquidized asphalt; a'series of rollers carrying astrip of absorptive material, said rollers being adapted to submergesaid strip in said asphalt within said tanks to form coatings of saidasphalt on said strip;

member; applying a second ing of adhesive material to said shinglemember; removing a portion of said adhesive coating, thus providing saidshingle member with a coated and an uncoated portion; applying agranular coating to said shingle adhesive coating to said shinglemember; and applying a second granular coating thereto.

11. A process of producing a composite shingle member, comprising:applying a coating of adhesiv'e'material to said shingle member;removing said adhesive coating from a portion of said shingle member,thus providing said shingle member with a coated and an uncoatedportion; applying a granular coating to said shingle member; applying asecond adhesive coating to said shingle member; and applying a secondgranular coating thereto.

12. A process of producing a composite shingle member, comprising:applying a coating of adhesive material to said shingle member; removinga portion of said adhesive coating, thus providing said shingle memberwith a coated and an uncoated portion; applying a granular coating tosaid shingle member; applying a second adhesive coating to said shinglemember; removing a portion of said second adhesive coating from a partof said shingle member so that said second adhesive coating will berelatively thin at the portion of said shingle member from which saidfirst coating of adhesive material was removed; and applying a secondgranular coating thereto.

13. A process of producing a composite shingle member, comprising:applying a coating of adhesive material to said shingle member; removingsaid adhesive coating from a port-ion of said shingle member, thusproviding said shingle member with a coated and an uncoated portion;applying a granular coating to said shingle member; applying a secondadhesive coating to said shingle member; removing a portion of saidsecond adhesive coating from a part of said shingle member so that saidsecond adhesive coating will be relatively thin at the portion of saidshingle member from which said first coating of adhesive material wasremoved; and applying a second granular coating thereto.

In testimony whereof. I have hereunto set my hand at Los An geles,California, this 20th day of August, 1929.

RAY W. CONANT.

